Method to uniformly debundle and evenly distribute high fiber count carbon tow

ABSTRACT

A process for producing a carbon sheet molding compound (SMC). An SMC manufacturing line including at least one conveyor line for laying up SMC resins on a carrier film is provided. A chopped carbon fiber which is evenly distributed using dehumidified supply air and using a pressurized air venturi apparatus which is used to debundle and randomize the carbon fibers, onto the resin on the carrier film as the carrier film moves along the conveyor.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a National Stage of PCT International ApplicationNo. PCT/IB2017/053283, filed Jun. 2, 2017, which claims the benefit ofU.S. Provisional Patent Application No. 62/345,481, filed Jun. 3, 2016and U.S. Provisional Application No. 62/445,063, filed Jan. 11, 2017.The disclosures of the above applications are incorporated herein byreference.

FIELD OF THE INVENTION

The present invention relates to a process for producing a carbon sheetmolding composition.

BACKGROUND OF THE INVENTION

The uniform debundling of Carbon Tow in SMC manufacturing is critical toachieve consistent and high mechanical properties required in structuralapplications. Individual air-venturi's are used to amplify andaccelerate the air which is used to debundle and transport the carbonfibers. Variation in the velocity of air from individual air-venturi's,result in non-uniform opening of the chopped carbon. Non-uniform openingof carbon tows result in uneven wetting of carbon fibers with the matrixresin. If the carbon fiber bundles are not opened up well, the resinwill be restricted in reaching the individual carbon fibers and will notimpregnate them fully, and this results in dry carbon fibers in themanufactured SMC. Also if there is a variation in the debundling of thecarbon bundles across the film, the mechanical properties will benegatively impacted. Variations in the air velocity used for debundlingthe carbon also leads to a non-uniform distribution of carbon across thecarrier film. Carbon tows which are partially debundled tend to be heavyand drop directly under the cutter resulting in a higher carbon densityat that location. The over debundling of carbon results in lightercarbon which tends to float from chamber to chamber and settle down atrandom locations resulting in highly variable carbon density at theintended location under the cutter. These conditions often result inundesirable high/low carbon concentrations. In these cases the highcarbon locations become resin starved and low carbon locations becomeresin rich. The high velocity air coming out of the transvector needs tobe balanced and excess air needs to be exhausted out of the chamber inorder to prevent the carbon fiber from crossing from cutter to cutter.To do this two exhausts were set up, one before the chopper and oneafter the chopper. The exhaust openings were adjusted to neutralize theair pressure from the transvector and prevent the chopped fiber frombeing pulled in one particular direction or side.

Additionally, the humidity in the ambient air can vary depending on thetime of the day, year and season. The sizing on the carbon tends toabsorb moisture under high humidity conditions and this interferes withthe reaction of the isocyanate and the resin and results in reducing theadhesion of the resin to the carbon, which is also undesirable.

Also problematic is the formation of wrinkles in the carrier film as theplastic is pulled around pulleys and over the line under tension.Wrinkles in the carrier film prevent uniform spreading of the resinacross the film. These areas do not become saturated in resin and createresin starved areas in the SMC.

In order to solve these problems it is the objective in the presentinvention to: 1) provide uniform opening of high yield chopped carbonyarns with as small as 12,000 filaments per yarn to greater than 50,000filaments; 2) provide uniform and consistent distribution of the carbonacross carrier film; 3) provide a reduced level of humidity in the airused to debundle the carbon; and, 4) to provide uniform spreading ofresin on the carrier film.

SUMMARY OF THE INVENTION

A process for producing a carbon sheet molding composition comprisingthe steps of:

Providing an SMC manufacturing line including at least one conveyor linefor laying up SMC resins on a carrier film;

Providing a chopped carbon fiber which is evenly distributed usingdehumidified air in conjunction with and air amplified venturi systemused to transport the fiber tows into the cutting chambers; as well as,introduce energy needed to open the carbon bundles, onto a uniform resinfilm transported on a carrier film that moves along the SMC linesconveyor.

Further areas of applicability of the present invention will becomeapparent from the detailed description provided hereinafter. It shouldbe understood that the detailed description and specific examples, whileindicating the preferred embodiment of the invention, are intended forpurposes of illustration only and are not intended to limit the scope ofthe invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will become more fully understood from thedetailed description and the accompanying drawings, wherein:

FIG. 1 is a schematic view of the process in accordance with the presentinvention;

FIG. 2 is a schematic illustration of the air flow used in accordancewith the present invention;

FIG. 3 is a plan view of the air-amplifiers, chopper and dividerapparatus used in the process of the present invention;

FIG. 4 is a illustrative view of the divider system used in the processof the present invention;

FIG. 5 is a sketch of divider designs useful in the present invention;

FIG. 6 is a perspective view of the flow meter air control apparatus forcontrolling air flow to the air amplifiers in the present invention;

FIGS. 7-9 are views illustrating the process of controlling orminimizing the formation of wrinkles on the carrier film;

FIGS. 10 through 14 are graphs and test results supporting the examplesand comparative examples set forth herein;

FIG. 15 is a perspective view of a nip roller, in accordance with anembodiment of the present invention; and,

FIG. 16 is a perspective view of the nip rollers used after the doctorboxes, adjacent to the film edges, in accordance with the presentinvention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following description of the preferred embodiment(s) is merelyexemplary in nature and is in no way intended to limit the invention,its application, or uses.

Referring to the figures generally, a process for producing a carbonsheet molding compound (SMC) is generally shown at 10. The processcomprises the steps of first providing an SMC manufacturing line 12including at least one conveyor line 14 for laying up SMC resins 16 on acarrier film 18. A chopped carbon fiber 20 from a chopper systemindicated generally at 21 is provided which is evenly distributed usingdehumidified air 22 by a transvector apparatus or air-amplifierindicated generally at 24 onto the resin on the carrier film 18 as thecarrier film 18 moves along the conveyor 14. An exhaust system 23 isalso provided for balancing air pressures.

A cutter 26 is provided for chopping raw continuous carbon fiber strands28 into predetermined sizes suitable for adding to the SMC composition30. The cutter 26 has dividers 32 extending down to the exit side of thechopper for assistance with distribution of the chopped carbon fibers 20as best illustrated in FIGS. 2-4.

As best shown in FIGS. 2-3 and 6, the air-amplifier apparatus has an airflow control system 27 with a series (A-H) of controllable air outletsfor adjusting the flow of chopped carbon fiber evenly through thedividers 32 and onto the resin containing carrier film 34 moving alongthe conveyor 14. FIG. 3 depicts airlines (A′-H′) to respectivetransvectors 25. More or less than eight transvectors depending on theapplication are contemplated without departure from the scope of thepresent invention. The air flow control 27 controls compressed air toindividual transvectors 25. Preferably, there are a plurality ofcompressed air channels to the transvectors, e.g., 8; one for eachtransvector 25. Preferably, the air flow control 27 receives compressedair from a compressed air storage 45. The transvectors 25 receivecompressed air from the airlines (A′-H′) and also carbon and dry air 22provided from a dehumidifier 31 passed through a creel box 35.

As best shown in FIG. 2, a duct 33 if provided from the creel box 35 tothe inlet of the chopper box 37. This duct 33 makes it possible tolocally control the environment. A dehumidifier 31 was integrated at theentry side of the creel box 35. The dry air from the dehumidifier 31 wascontinuously passed through the creel box 35 and through a plenum to thechopper system 21 and leading to the transvectors 25. Trials conductedwith higher humidity ambient air and dehumidified air showed that themechanical properties increased with introducing dehumidified air (seeFIGS. 13-14).

The process 10 also includes a mechanism 36 for depositing a secondresin coated carrier film 38 after the chopped carbon fiber is depositedon to the resin coated carrier 34 moving along the conveyor 14. Thecarrier films can pass between compaction rolls indicated generally at29, such as parallel or offset series of upper/lower rolls with thecarrier films operably therebetween, and the SMC composition 30 wound bya winder apparatus.

As illustrated in FIG. 7, wrinkles 60 can form on the carrier film asthe carrier film unwinds from the roll. This can create resin-lackingstreaks on the carrier film. Low resin areas cause blisters and weakstructural properties.

As shown in FIGS. 8A-9, according to an embodiment of the presentinvention, an anti-wrinkle apparatus shown generally at 40 is providedfor removing wrinkles 60 in the SMC product by providing at least onespreader roll 46 with angularly displaced ends 42 and 44. As thespreading roll 46 rotates with the film, the film enters one side of aparticular length and leaves the other side of another particular lengthto remove the wrinkles. Alternatively, the ends are not angled.

Referring to FIGS. 15-16, according to a preferred embodiment of thepresent invention, an anti-wrinkle apparatus shown generally at 100 isprovided for removing the wrinkles in the carrier film by providing atleast one set of first and second nip rollers 102, 102B on the two edgesof the film 48 and 50. These nip rollers help remove wrinkles caused bythe tensioning of the film being pulled by the compactor. The filmtravels between the first and second nip rollers 102 and 102B.

-   -   The nip rollers 102,102B are tensioning rollers placed at a        predetermined angle to each side of the film 48,50. The angled        nip rollers tend to pull the film outwards thereby limiting or        eliminating the wrinkles caused by the pulling of the film by        the compactor.

A particularly preferred nip roller is Adjusta-Pull® Anti-Wrinkle systemmanufactured by Converter Accessory Corporation of Wind Gap, Pa.

According to a most preferred embodiment of the present invention, thecombination of at least one film spreader roll 40 and at least one pairof nip rolls 102,102B on each side of the film is provided to eliminatefilm wrinkles.

The film spreading roll 46 functions using a membrane that articulatesmechanically as the film is wound around the roll. This tensions thefilm radially and was positioned before at least one of the doctorboxes, e.g., box of resin 16 and upper resin box. As well the anglednip-rolls 102,102B create radial tension by spreading the film betweenan elastomeric and metallic roll. These were positioned after at leastone of the doctor boxes. Trials were conducted with the film spreadingroll and nip rollers resulting in a smooth flat film which improved theuniform distribution of resin.

The film spreading roll 46 is an elastomeric covered spread roll.

A particularly preferred film spread roll is Wrinkle-Stop® manufacturedby Converter Accessory Corporation (CAC) of Wind Gap, Pa.

In accordance with the present invention the process of the presentinvention provides improved manufacturing and carbon SMC materialsincluding: Quasi isotropic properties, being the ability to use singlelayer and achieve quasi isotropic properties; it provides a uniformcarbon distribution; films produced include a lower coefficient ofstandard deviation in the properties; a consistent quality of Carbon SMCis produced with substantially no dry fibers or resin rich areas; and,the final SMC has superior mechanical properties.

EXAMPLES

Traditional cot roll cutters do not use air to open fibers. Choppedcarbon without the aid of air debundling tend to have directionalproperties unlike debundled carbon which have quasi isotropicproperties. Also large bundles of carbon are difficult to wet out, solower yield carbon tows from 3-12K can be chopped with this style ofcutter. However the cost of the carbon fiber product goes up.

The other cutters commercially available do not use air and they do notdebundle the carbon. Those choppers just chop the carbon and hence theproperties of SMC made from these choppers are directional. Initialtrails were conducted with ambient air. Ambient air can have a highlevel of humidity. The sizing on the chopped carbon absorbs the humidityand causes variations in the mechanical properties due to a reduction inthe interface properties which affected the adhesion of the fibers tothe resin. Commonly Magnesium Oxide is used in SMC with vinyl ester (VE)resin to thicken the resin, this chemistry does not bond well withcarbon resulting in lower properties. The thickener employed in thisinnovative system uses an isocyanate which bonds with the fibersresulting in higher properties at similar fiber concentrations. Thisisocyanate thickener reacts negatively with the moisture absorbed by thesizing on the carbon, resulting in poor bonding between the resin andthe carbon.

The film conveyor employed flat idler rolls and a banana type roll toattempt to minimize film wrinkles. These devices were ineffective ineliminating the creation of small wrinkles in the film. To resolve theissue a combination of side mounted nip-rollers 102,102B after thedoctor box, positioned at approximately 45° to the line direction of thefilm, and the addition of a full width film spreading roll 46 before thedoctor box, eliminates the problematic film wrinkles. It is understoodthat alternative positions in the system are contemplated depending onthe application without departure from the scope of the presentinvention.

The carbon fibers have a predetermined length dependent upon theparticular application. Generally, the fiber length is 13 to 75millimeters, typically, 25-75 mm, preferably about 25 mm. However,shorter or longer fiber lengths are contemplated depending on theapplication without departure from the scope of the present invention.

The chopper 37 is an air assisted carbon chopper. A preferredmanufacturer of the carbon chopping system is Brenner Internationalhaving a place of business in Newark, Ohio. The fiber chopping systemuses high velocity air from transvectors 25 and individual cuttingchambers 39 to debundle the carbon tows. One of the advantages ofdebundling individual carbon fiber from the carbon tow is that the resindistribution between individual fibers are fairly uniform. The nondebundled carbon tow tend to have resin starved area within individualfiber in a tow and resin rich area between two non debundled tow. Thiscreates a non uniform resin distribution which results in lowermechanical properties. The advantage of using air to debundle the carbonis that it helps to create a highly turbulent air stream thatcontributes to randomizing the carbon after chopping and thisrandomization reduces variation in the quasi-isotropic properties ascompared to directional properties achieved using other fiber cutters.As a result the layers of SMC do not need to be stacked randomly toachieve quasi-isotropic properties. The challenge with using air todebundle the carbon is that the air currents can contribute to erraticflow and introduce other sources of variation. The cutter in thisinvention consists of eight chambers 39 and each chamber has eightindividual chopping blades 62, a transvector 25 or air-amplifier assiststhe transportation of the carbon tow in to the cutter, and a bushingthrough which the carbon tow and air flows. The transvector amplifiesthe air flow and speed (1-4×) which helps in debundling the carbon as itgoes through the chopper. Individual chopper chambers consist of eightblades which continuously chop each of the carbon tows, which are fedthrough the air-amplifiers 25. The amplification of each transvector 25is created using a venturi effect. A controlled flow rate of air issupplied to the side mounted inlet, an internal orifice gap creates adrop in pressure which draws additional air into the axial chamber ofthe transvector. Adjusting the venturi gap with calibrated shims, e.g.,0.002″ and 0.003″ thick, makes it possible to tune the amplification ofeach transvector 25 and corresponding exit velocity. It was found thatthe amplification of individual transvectors 25 were slightly different.The transvector 25 used for amplifying the air requires adjustment andcalibration to achieve a uniform amplification on all transvectors 25.This was done by setting the input velocity and measuring the outputvelocity of the eight transvectors 25. In order to achieve the sameoutput velocity, the venturi gap was calibrated using shims (3-10thou.). Further adjustment of the output velocity of each transvector 25was done by adjusting the air flow meter 27 which controls the inlet airflow to the transvector 25. By controlling the airflow and velocity itwas possible to uniformly debundle each chopped carbon tow individually,and get a more uniform distribution of the carbon from zone to zone.

Acrylic dividers 32 extending below the chopper, were installed tofurther separate the eight cutting zones. This separation andconfinement above the carrier film 14 helped to straighten the fallingof the random carbon fibers 20, minimizing the carbon fibers 20 fromfloating from one zone 39 to another zone 39 (e.g., see FIGS. 3-4). Anyother suitable material for dividers are contemplated depending on theapplication without departure from the scope of the present invention.The geometry of the dividers 32 were optimized to minimize carbon fibers20 from getting caught and sticking to the edges of the dividers as wellas the length to provide straightening as the fibers fall but an abilityto overlap the adjacent cutters. If the dividers were too close to thesurface film, they created individual rows of chopped carbon whichresembled corn rows. This typically created resin channels. To preventthis, the length of the dividers need to be optimized to promotestraightening with some overlapping of the falling carbon. Also thecontours on the dividers had to be shaped in such a way that the carbondid not get trapped between the dividers and the chopper. The airvelocity in the chamber was measured; as well as, the exhaust systemsflow rate and the inlet air due to the transvectors. The objective wasto balance the airflow to minimize turbulence in the chamber. The airvelocity of the exhaust was adjusted using dam gate styled dampers. Theair velocity in the exhaust was maintained at such a level so that therewas no significant air drafts in the cutter box and only the excess airand carbon dust were exhausted.

Trials were conducted by varying the air velocity on the individualcarbon chopper zones (zones indicated generally at 39 in FIG. 3). It wasobserved that air flow between 4.5 to 6.2 cubic feet per minute (cfm)was required for optimal opening (e.g., FIGS. 2-3 and 6). Again air flowto the individual chopper had to be calibrated between these two rangesto find the optimum air flow for the particular chopper zone 39. Thedistribution of the carbon was also controlled by installing dividers 32between each individual chopper zone 39 (e.g., FIG. 4). The initial setof dividers 32A-32C (e.g., length 11-13 inches and narrowest widthbetween 5.4-6.3 inches) were designed in such a way that there was avery small lower gap between the base of the chopper and the divider(e.g., FIG. 5). This resulted in carbon getting trapped between thedivider and the chopper. The trapped carbon continued to accumulate andprevented the free falling of chopped carbon. The accumulated carbonthen either falls as a bunch or becomes so large that it eventuallychokes up the cutter. The gap between the chopper base and the dividerwas gradually increased until the carbon did not get trapped. Also thelength of the divider had to be adjusted. If the length of the dividerwas too long, it result in creating visible compartments of fibersresembling corn rows of carbon between the dividers. These corn rowswere then visible in the compounded sheet and resulted in variations offiber content. If the length of the divider was too short the carbonwould cross from one zone 39 to the next in an uncontrolled fashion. Theair movement inside the chopper box was controlled by adjusting the airflow in the transvector 25 and controlling the two exhausts 41 and 51(see FIG. 2) to balance the air pressure and minimize either overexhausting the carbon or forcing the carbon out of the line. Theexhausts 41,51 are coupled to an air vacuum system 43.

Trials conducted without dividers and with dividers showed that thecarbon fiber distribution was more uniform and closer to thepredetermined target, e.g. 50%, with the introduction of dividers (seeFIGS. 10-11 and 12).

The divider 32 and distance to the carrier film 14 has predetermineddimensions and contours suitable and adaptable to the particularapplication. As best shown in FIG. 4, in an embodiment of the presentinvention, the distance between each divider 32 and carrier film 14(‘D’) is generally 20 to 30 inches, typically, 21-25 inches, preferably22-24 inches, most preferably 23 inches. The width (‘W’) of the thickestportion of the divider 32 is generally 3.5 to 6.5 inches, typically, 4to 6 inches, preferably 5 to 5.75 inches, most preferably about 5.5inches. The length (‘L’) of the divider 32 is generally 15 to 23 inches,typically, 16 to 20 inches, preferably 17-19 inches, most preferablyabout 18 inches. Preferably, the top portion 47 of the divider adjacentthe cutter 26 is contoured and has a width (′W and/or W″) smaller thanthe lower portion of the divider 32 e.g., to a width of 2 to 3 inches,preferably 2 to 2.50 inches. The divider 32 is generally not more than0.25 inches thick, typically about 0.2 inches thick, preferably lessthan 0.15 inches thick, most preferably not more than 0.13 inches thick.The gap, indicated generally at ‘G’, between the bottom of the cutter isgenerally not more than 2 inches, typically, not more than 1.5 inches,preferably, not more than 1 inch, most preferably 0.45 to 0.75 inches.Preferably, the width of the chambers 39 or distance between adjacentdividers 32 is generally not more than 5 inches, typically not more than4 inches, preferably not more than 3 inches, most preferably, 3 inches.Other dimensions are contemplated depending on the application withoutdeparture from the scope of the present invention.

In accordance with the present invention the process of the presentinvention provides improved techniques to manufacture carbon SMCmaterials including: Quasi isotropic properties, being the ability touse single layer and achieve quasi isotropic properties; it provides auniform carbon distribution; Parts molded with this SMC compound had alower coefficient of standard deviation in the properties; a consistentquality of Carbon SMC is produced with substantially no dry fibers orresin rich areas; and, the final SMC has superior mechanical properties.

The description of the invention is merely exemplary in nature and,thus, variations that do not depart from the gist of the invention areintended to be within the scope of the invention. Such variations arenot to be regarded as a departure from the spirit and scope of theinvention.

What is claimed is:
 1. A process for producing a carbon sheet moldingcomposition comprising the steps of: a. providing a sheet moldingcompound (SMC) manufacturing line including at least one conveyor linefor uniform spreading SMC resins on a carrier film with uniformtensioning, devoid of wrinkles, achieved using an articulatingelastomeric roll located at a lead of doctor boxes and at least one pairof side nip rolls located at an exit of the doctor boxes; b. providing aliquid resin consistently spread on the carrier film without defectscaused by wrinkles in the carrier film; c. providing a cutter forchopping raw carbon fiber strands into predetermined sizes suitable foradding to the liquid resin; and d. chopping the carbon fiber strands toprovide chopped carbon fiber; and e. distributing said chopped carbonfiber to said liquid resin, which said chopped carbon fiber is evenlydistributed and randomized using dehumidified air supplied to atransvector apparatus; and wherein the cutter includes individualchopper chambers having dividing walls between the chopper chambers forassistance with the distribution of the chopped carbon fiber, andwherein each dividing wall is about 21 to 25 inches from the carrierfilm to allow some overlapping of distributed chopped carbon fiber. 2.The process of claim 1, wherein the predetermined sizes are in a rangeof from about 13 mm to up to 75 mm long.
 3. The process of claim 1,wherein each chopped carbon fiber length is about 25 mm.
 4. The processof claim 1, wherein a gap between a bottom of the cutter and one of thedividing walls is in a range of about 0.45 to 0.75 inch.
 5. The processof claim 1, wherein said transvector apparatus has a series ofcontrollable air outlets to a plurality of transvectors for adjusting aflow of chopped carbon fiber evenly between said divider walls and ontothe liquid resin containing carrier film moving along the conveyor. 6.The process of claim 5, wherein the dehumidified air is also supplied tothe plurality of transvectors respectively to provide a reduced level ofhumidity in forced air used to debundle the chopped carbon fiber.
 7. Theprocess of claim 6, wherein a dehumidifier is integrated at an entryside of a creel box and dehumidified air from the dehumidifier is passedthrough the creel box through a plenum to an inlet of a chopper.
 8. Theprocess of claim 5, further comprising controlling air movement within achopper chamber by adjusting an air flow to the plurality oftransvectors and controlling at least two exhausts operably coupled toan air vacuum system for balancing air pressure inside the chopperchamber and minimizing over exhausting.
 9. The process of claim 5,wherein an air flow is about 4.5 to 6.2 cubic feet per minute.
 10. Theprocess of claim 1, further comprising a mechanism for depositing asecond resin coated carrier film free of wrinkles, after the choppedcarbon fiber is deposited onto the liquid resin coated carrier filmmoving along the conveyor.
 11. The process of claim 1, wherein theprocess provides uniform debundling of high yield chopped carbon yarnswith equal to or greater than 12,000 filaments per yarn.
 12. The processof claim 1, wherein the process provides uniform opening of high yieldchopped carbon yarns with equal to or greater than 50,000 filaments peryarn.
 13. The process of claim 1, wherein each of said at least one pairof side nip rolls comprises a first roll and a second roll positioned atabout 45 degrees to a line direction of the carrier film, wherein thefirst roll and second rolls are on opposite edges of the carrier filmwhich helps in spreading the film and removes wrinkles.
 14. A processfor producing a carbon sheet molding composition comprising the stepsof: a. providing a sheet molding compound (SMC) manufacturing lineincluding at least one conveyor line for uniform spreading SMC resins ona carrier film with uniform tensioning, devoid of wrinkles, achievedusing an articulating elastomeric roll located at a lead of at least oneresin doctor box and a plurality of side nip rolls with at least one ofeach nip roll on each side of the carrier film at an angle to side edgesof the carrier film, said plurality of side nip rolls located at an exitof said at least one resin doctor box; b. providing a chopper systemwith a plurality of dividers defining a plurality of chambers to assistwith distribution of chopped carbon fibers; c. providing a first exhaustbefore the chopper system and a second exhaust after the chopper system,wherein exhaust openings neutralize air pressure within the choppersystem to prevent chopped carbon fiber from being pulled in oneparticular direction or side of the chambers; d. providing a liquidresin film, consistently spread on the carrier film without defectscaused by wrinkles in the carrier film; and, e. providing a choppedcarbon fiber which is evenly distributed and randomized onto the resincarrier film using dehumidified and amplified air flow supplied to atransvector apparatus adjacent the plurality of chambers.
 15. Theprocess of claim 14, wherein said transvector apparatus has a series ofcontrollable air outlets coupled to a plurality of transvectors foradjusting the flow of high velocity air to each of the plurality ofchambers.
 16. The process of claim 14, further comprising a mechanismfor depositing a second resin coated carrier film free of wrinkles,after the chopped carbon fiber is deposited on to the resin coatedcarrier moving along the conveyor.
 17. A process for producing a carbonsheet molding composition comprising the steps of: providing continuouscarbon fiber strands; providing at least one resin material; providingat least one carrier film; providing a sheet molding compound (SMC)manufacturing line including at least one conveying system for movingthe at least one carrier film along the SMC line; providing at least onearticulating spreader roll with angularly displaced angled ends locatedbefore a doctor box for delivering the resin material; providing atleast one pair of side nip rolls with a nip roll on each side of thecarrier film at an angle relative to side edges of the carrier film,said at least one pair of side nip rolls located at an exit side of thedoctor box, said at least one articulating spreader roll and at leastone pair of side nip rolls keeping the carrier film under tension andpreventing or removing any wrinkles in the carrier film; providing achopper system for chopping the continuous carbon fiber strands, saidchopper system including a plurality of chambers each with a cutter forchopping the strands and dividers extending downward to an exit side ofthe chopper system; providing a plurality of transvectors with air flowcontrol and operable to receive compressed air and dehumidified air,said plurality of transvectors adjacent to the plurality of chambers todeliver air of predetermined velocity to each of the plurality ofchambers for debundling chopped carbon fiber; providing an exhaustsystem operable to balance air pressure from the plurality oftransvectors and exhaust excess air from the plurality of chambers toprevent the chopped carbon fiber from crossing from one chamber to anext of the plurality of chambers; depositing the at least one resinmaterial onto the at least one carrier film as the conveyor moves thecarrier film under tension along the conveyor; delivering dehumidifiedair and the compressed air to the plurality of transvectors anduniformly distributing debundled chopped carbon fibers onto the resin onthe carrier film, wherein the dividers in combination with the pluralityof transvectors provide the uniform distribution of debundled choppedcarbon fibers onto the resin on the carrier film.